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General task requirements for systems which treat cooling lubricants: Minimization of disposal costs and maximum resource conservation.
Specific customer requirements:
- Notwendige Parameter für Kreislaufführung müssen erreicht werden bzw. Einleitgrenzwerte prozesssicher unterschritten werden
- Considerable cost reduction in the area of used emulsion
- Necessary cycle management parameters need to be achieved, or prescribed maximum values must not be exceede
- Recycling of residual substances (concentrates)
- Reduction of wastes
- Short amortisation periods
- Distillate temperature below 35 °C when discharged
Besonderheiten bei Emulsionsaufbereitung mittels Verdampfer:
If the emulsion is stored for a longer period of time before it is treated, it will begin to decompose. If this happens, the pH-value usually drops to acidic values, making it necessary to raise the pH.
If the emulsion is used again: The chemicals must be adjusted to the distillate according to the chemical manufacturer’s regulations to prevent foam from forming. If necessary, fresh water can be added to make up for the loss.
If discharged: It is necessary to after-treat the distillate using residual oil separators or the PCS Unit.
The used cooling lubricants are collected in a storage tank. Depending on how dirty the emulsion is, it may be necessary to install a belt filter upstream, or a bag filter downstream of the storage tank.
The free oil phase which develops in the storage tank can be siphoned off. Alternatively, the free oil can be skimmed off.
In the Evaporator ET, the oil, dirt and mixed in additives are separated from the water. A PCS Unit is installed downstream from the ET in order to reduce the amount of volatile elements in the distillate.
The resulting distillate can be used again according to the manufacturer’s specifications. Or, it can be discharged in compliance with legal regulations.
Because of its high oil content, the concentrate which has been produced is recycled.
System ET: Goals which have been reached in practice
- Minimal operation costs thanks to extremely low energy consumption
- Best quality distillate achieved through integrated residual oil separators and air ventilation systems
- High concentration, high oil content, the concentrate is made recyclable
- Short amortisation periods thanks to the high efficiency of the system
- Through optimal heat recovery in the System ET, the distillate temperature is maintained at a temperature (reference 20°C) considerably lower than the prescribed maximum temperature of 35°C.